Mechanical system that fluidizes, mixes, coats, dries, combines, chemically reacts, and segregates materials

ABSTRACT

The present application is directed towards systems for adding components to materials being fluidized in a vibratory mixer by use of atomizers or sprayers. A mechanical system can fluidizes, mix, coat, dry, combine, or segregate materials. The system may comprise a vibratory mixer, mixing vessel containing a first material and a sprayer to introduce a second material. The vibratory mixer may generate a fluidized bed of a first material and the sprayer, coupled to the mixing vessel, may introduce a second material onto the fluidized bed to mix the materials in a uniform and even fashion.

RELATED APPLICATIONS

The present application is a continuation of, and claims the benefit andpriority of, U.S. patent application Ser. No. 16/157,919, filed Oct. 11,2018, which is a divisional of U.S. patent application Ser. No.14/402,505, filed Nov. 20, 2014, which is the U.S. National Stage ofInternational Application No. PCT/US2013/043755, filed May 31, 2013,which claims priority to U.S. Patent Provisional Application No.61/689,256, filed on May 31, 2012, entitled “Mechanical System ThatFluidizes, Mixes, Coats, Dries, Combines, Chemically Reacts, orSegregates Materials.” Each of the foregoing applications isincorporated by reference in its entirety for all purposes.

FIELD

The present application is in the technical field of coating, drying,and mixing particles.

BACKGROUND

Current methods and systems for spray coating applications do notproduce uniformly mixed, coated or combined materials. These methodshave particular difficulty when trying to coat smaller particlesuniformly. Many fluidizers and tumblers do not adequately create auniform motion to coat the materials evenly. Similarly, current methodsfor combining materials using chemical reactions are costly and timeconsuming. Under traditional methods, excess reaction gas can be wastedbecause the reaction gas is used for both fluidization as well asreaction. This may sometimes require the addition of other materials tocreate the fluidization using conventional fluidizers. The othermaterials added with conventional fluidizers would potentially addcontaminants, as well as waste materials that would have normally beenreacted.

BRIEF SUMMARY

The present application is directed towards mechanical systems andmethods that fluidize, mix, coat, dry, combine, chemically react and/orsegregate materials utilizing vibratory mixing technology. Vibratorymixing technology provides a unique method to combine, mix, dry, and/orcoat materials without the use of mixing blades or impellers. Theapplication uses an acoustic mixer to produce low frequency acousticenergy that mixes materials in a uniform and even fashion. The systemfurther includes a plurality of nozzles, filters, methods to heat andcool, vents, partial and full vacuum vessels, and/or pressure vesselsthat can be tuned to desired outcomes for various application.

In one aspect, the disclosure is related to a system for spray coating amaterial. The system includes an acoustic means for generating afluidized bed in a mixing vessel. The fluidized bed includes a firstmaterial. The system also includes a means for spraying a secondmaterial into the mixing vessel and onto the fluidized bed. In someimplementations, the acoustic means for generating a fluid bed in amixing vessel is capable of oscillating at a range of about 50 Hz toabout 70 Hz.

In some implementations, the system further comprises a means for mixingthe first material and the second material in a bulk flow pattern. Thevibratory mixing system can be configured to induce both micro-mixingand bulk mixing of the first material and the second material. In someimplementations, the micro-mixing can contribute to and facilitate thebulk mixing. In some further implementations, materials can beintroduced into the mixing vessel to direct the bulk flow pattern.

The means for spraying may be coupled to the mixing vessel. The meansfor spraying may introduce the second material to the mixing vesselthrough the top of the mixing vessel, the side of the mixing vessel, orthrough the bottom of the mixing vessel. In some implementations, themeans for spraying may comprise a plurality of spray nozzles. In otherimplementations, the system may comprise a means for introducing gas tothe mixing vessel.

The system may further comprise a means for controlling the pressurewithin the mixing vessel. The mixing vessel may be coupled to a vacuumline that provides a vacuum source. In some implementations, the systemmay further comprise a vent coupled to the mixing vessel. In otherimplementations, the mixing vessel may be sealed.

The system may further comprise a means for cooling the mixing vesselcoupled to the mixing vessel. In some implementations, the system maycomprise a means for heating the mixing vessel coupled to the mixingvessel.

In some implementation, the system further comprises a means fordetecting mixedness of the first material and the second material in themixing vessel to determine the current mixing stage. In otherimplementations, the system of may comprise a means for measuring thetemperature of the materials in the mixing vessel.

In another aspect of the present disclosure, the system comprises amixing vessel containing a first material, a vibratory mixer forgenerating a fluidized bed in the mixing vessel, and a sprayer forintroducing a second material into the mixing vessel. In someimplementations the vibratory mixer is capable of oscillating at a rangeof 50 Hz to 70 Hz.

The vibratory mixer may comprise a driver assembly, said driver assemblybeing movable in a first linear direction and in an opposite lineardirection. The vibratory mixer may also comprise a plurality of motorassemblies comprising a motor having a motor shaft to which an eccentricmass is attached, each of said eccentric masses having a centroid, eachof said motor assemblies being rigidly connected to said driver assemblyand being adapted to rotate the centroid of its eccentric mass in aplane that is parallel to another plane in which said first directionand said opposite direction lie.

Additionally, the vibratory mixer may comprise a payload assembly, saidpayload assembly being movable in the same directions as said driverassembly and being movably connected to said driver assembly andconfigured for placement of the mixing vessel thereon. The vibratorymixer may comprise a plurality of reaction mass assemblies, eachreaction mass assembly being movable in the same directions as saiddriver assembly and being movably connected to said payload assembly.Each of said eccentric masses may have substantially the same weight andinertial properties, and wherein the eccentric masses are rotatable atsubstantially the same rotational speed in opposite rotationaldirections and around axes that lie in the same plane and, duringrotation, are operative to produce a first force on said driver assemblyin said first direction and a second force on said driver assembly insaid opposite direction and substantially no other forces on said driverassembly.

The vibratory mixing system may mix the first and second material in abulk flow pattern. The vibratory mixing system can be configured toinduce both mirco-mixing and bulk mixing of the first material and thesecond material. In some implementations, the micro-mixing cancontribute to and facilitate the bulk mixing, which can also be includedin the micro-mixing and the bulk mixing.

The sprayer may be coupled to the mixing vessel. In someimplementations, a plurality of sprayers may be coupled to the mixingvessel. In other implementations, the system may include a gas sweepfeed to introduce a gas to the mixing vessel.

The vibratory mixing system may further comprises a vacuum line toprovide a vacuum source. The fluidized bed may be generated by using apartial vacuum, full vacuum or high pressure in the mixing vessel.

In some implementations, the vibratory system may comprise a ventcoupled to the mixing vessel. In other implementations, the mixingvessel may be sealed to create pressure in the mixing vessel.Additionally, a pressure relief valve may included in the system tocontrol pressure levels in the mixing vessel. In some implementations,the system may further comprise a filter coupled to a vent, pressurerelief valve or a vacuum line.

The vibratory mixing system may further comprise a cooling jacketcoupled to the mixing vessel for cooling the mixing vessel. In someimplementations, the system may comprise a heating jacket coupled to themixing vessel for heating.

In some implementations, the vibratory mixing system may comprise a nearinfrared (NIR) sensor to detect mixedness of the first material and thesecond material in the mixing vessel. The NIR sensor may determine thecurrent mixing stage of the materials during operation. The vibratorysystem may comprise a temperature measuring device to detect thetemperature of the materials in the mixing vessel.

In another aspect of the present disclosure, a method for vibratorymixing a combination of materials is described. The method includesgenerating, by a vibratory mixer, a fluidized bed in a mixing vessel,the fluidized bed comprising a first material. The vibratory mixer maybe capable of oscillating at a range of 50 Hz to 70 Hz. The method alsoincludes spraying, by a sprayer, a second material into the mixingvessel and onto the fluidized bed. The sprayer may be coupled to themixing vessel. The method further includes controlling the pressure inthe mixing vessel by at least one of a vent, vacuum, pressure reliefvalve and seal. The method also includes detecting the mixedness, by anear-infrared sensor, of the first and second material in the mixingvessel.

BRIEF DESCRIPTION OF THE FIGURES

The foregoing and other objects, aspects, features, and advantages ofthe invention will become more apparent and better understood byreferring to the following description taken in conjunction with theaccompanying drawings, in which:

FIG. 1 is a front elevation view of a flat plate resonant mixer;

FIG. 2 is a right side sectional view of the flat plate resonant mixerof FIG. 1;

FIG. 3 is a perspective view of the flat plate resonant mixer of FIGS. 1and 2;

FIG. 4 is a front elevation view of the flat plate resonant mixer ofFIGS. 1-4;

FIG. 5 is a diagram representing the transmissive force responsebehavior of the flat plate resonant mixer of FIGS. 1-4;

FIG. 6 is a diagram representing the phase response behavior of the flatplate resonant mixer of FIGS. 1 4;

FIG. 7 is a perspective view of an alternative flat plate resonantmixer;

FIG. 8 is a side or front view of another alternative flat plateresonant mixer;

FIG. 9A is a schematic free body diagram of the flat plate resonantmixer of FIG. 1;

FIG. 9B is a schematic free body diagram of another example of a flatplate resonant mixer;

FIGS. 10A-17 are illustrative examples of various implementations of avibratory mixing system;

FIGS. 18-20 are illustrative examples of a vibratory mixing system usedfor drying;

FIG. 21 is another illustrative example of an implementation of avibratory mixing system;

FIG. 22 is another illustrative example of a vibratory mixing systemaccording to a drying application;

FIG. 23-24A are illustrative examples of various implementations of avibratory mixing system;

FIG. 24B is a graph of temperature ranges of the materials inside themixing vessel during operation of the mixing system;

FIGS. 25-33 are illustrative examples of various implementations of avibratory mixing system;

FIG. 34 is one implementation of a vibratory mixer-based spray coating;

FIG. 35 is a picture of an uncoated API material coated by traditionaltechniques; and

FIG. 36 is a picture of a coated API material coated by the vibratorybased spray coating system.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-4, show various views of examples of flat plate resonant mixer10. The resonant mixer 10 includes three independent movable masses(intermediate mass 11, oscillator mass 12 and payload 13) and fourdistinct spring beds or spring systems (payload mass to ground springs24, oscillator to intermediate mass springs 25, intermediate mass topayload springs 26 and intermediate mass to ground springs 27) that arehoused in a rigid structure 7. The oscillator mass 12 is situatedbetween the other two masses. The intermediate mass 11 is situated belowthe oscillator mass 12. The payload 13 is situated above the oscillatormass 12. In some implementations, all of the masses are constructed ofsteel or some comparable alloy.

The oscillator mass 12 is rigidly connected to two oscillator drives 38(e.g., two direct current (DC) servo motors) and is movably connected tothe intermediate mass 11 by the oscillator to intermediate massalignment struts 43, the oscillator to intermediate mass springs 25, tworetainers 40 and two locking nuts 41. The intermediate mass 11 ismovably connected to the rigid structure 37 by the intermediate mass tothe ground alignment struts 53. The intermediate mass to the groundsprings 27, the four retainers 40 and four locking nuts 41. The payload13 is movably connected to the intermediate mass 11 by the payload massto the intermediate mass struts 55, the payload mass to the intermediatemass springs 26, the two retainers 41 and the two locking nuts 40. Oneend of the payload mass to intermediate mass springs 26 rests on thestops 30 that are rigidly connected to the payload mass to theintermediate mass struts 55. The payload 13 is also movably connected tothe rigid structure 37 by the payload mass to the ground alignmentstruts 39, the payload mass to the ground springs 24, the four retainers40 and the four locking nuts 41.

FIG. 2 is a right side view of the resonant mixer 10. The intermediatemass 11 supports the payload mass 13 and the oscillator mass 12 inparallel. Furthermore, the oscillator mass 12 is not directly connectedto the payload mass 13. In FIG. 2, a portion of the cover of one of theservo motors 38 is not shown so that one of the motor shafts 57 and oneof the eccentric masses 56 are visible.

In another implementation, the resonant mixer 10 further includes amixing chamber 60. The mixing chamber 60 is attached to either theintermediate mass 11 or the payload 13. The mass that does not have themixing chamber 60 attached to it may also be divided into multiplemasses, each with its own resilient member attachment to attach the massto the mass that does not have the mixing chamber 60 attached to it.

Referring to FIGS. 3 and 4, another implementation of the resonant mixer10 is illustrated with elements deleted from the corner of resonantmixer 10 that is nearest the viewer in FIG. 3. In these views, both ofthe oscillator drives 38 are visible.

In yet another implementation, additional servo motors 38 can be addedto the resonant mixer 10 to provide for variability of the impulse forcewhile the resonant mixer 10 is in operation. With the addition of twomore servo motors 38 with the identical eccentric masses 56, total forcecancellation can be achieved. This is accomplished by setting all themotor axes to be parallel to one another with two motors rotatingclockwise and two motors rotating counterclockwise. The eccentric masses56 are selected so as to cancel out all forces at startup by setting thephase angle to 180 degrees for counter rotating pairs of motors. Whenthe motors have reached the desired frequency of rotation, the eccentricmasses 56 are moved out of phase, thus creating an impulse force. Thephase angle movement is accomplished by decelerating two of the motorsfor a fraction of a revolution and then reestablishing the selectedfrequency of rotation such that the eccentric masses no longer opposeeach other. Deceleration of the motors is accomplished through a servomotor motion control unit.

Operation of the various implementations of the resonant mixer 10, asillustrated in FIGS. 1-4, is achieved by the synchronized rotation bythe servomotors 8 of the eccentric weights 56 of equal mass and inertialproperties that are attached to each end of the shafts 57 of theservomotors 38. Synchronization of rotation of the two shafts 57 isaccomplished by electronic controls. The rotating shafts 57 of the twoservomotors 38 are oriented parallel to each other and are operated inopposing rotational directions with their eccentric weights 56 opposingeach other at the horizontal axis and coincident in the vertical axis.This arraignment produces vertical linear forces with horizontal forcecancellation.

The centerline axis of each of the shafts 57 and the centroid of theattached eccentric masses 56 form a mass plane. In the course of onerevolution, the initial position has the mass planes parallel to oneanother with the eccentrics 56 on each shaft above a motor plane definedby the two parallel motor shafts 57. At a quarter turn, the mass planesare coincident with the motor plane and the eccentric weights 56 of eachof the shafts 57 are nearest each other. The centrifugal forces createdby the eccentric masses 56 are translated in the motor plane. This forceis of the same magnitude but opposite direction for each of the shafts57. This effectively cancels the force in the plane of the motor. At onehalf a revolution, the mass planes are again perpendicular to the motorplane and the eccentrics 56 are all below the motor plane. Thecentrifugal force acting on each of the shafts 57 is in the samedirection, perpendicular to the motor plane. At three quarters of arevolution, the mass planes and the motor plane are again coincident butthe eccentric masses 56 of each of the shafts 57 are oriented away fromeach other. Here again, the centrifugal forces created by the eccentricmasses 56 are translated in the motor plane. This force is of the samemagnitude but opposite direction for each of the shafts 57. Thiseffectively cancels the force in the plane of the motor. At one fullrevolution, the mass planes are again perpendicular to the motor planeand the eccentrics 56 are all above the motor plane. The centrifugalforce acting on each of the shafts is in the same direction,perpendicular to the motor plane. The force acting perpendicular to themotor plane is translated vertically through connecting springs tointermediate mass 11. A further translation is then achieved throughlinear guides and springs from intermediate mass 11 to payload mass 13.The springs that comprise the spring beds 24, 25, 26 and 27 are selectedto optimize force transmission through the intermediate mass 11 to thepayload mass 13 and minimize transmission to the supporting structure 37and surrounding environment.

Operation at resonance is determined when the disparity between thepayload mass level of vibration and the driver mass level of vibrationis maximized. This resonant condition is dependent on the selectedspring/mass system. The springs characteristics and mass weights arechosen such that the resonant condition is achievable for theanticipated payload weight.

Operation at the resonant condition is not always required to achievethe level of mixing desired. Operation near resonance providessubstantial amplitude and accelerations to produce significant mixing.The desired levels of mixing are set by satisfying time requirementswith dispersion requirements. To mix faster or more vigorously,amplitude is increased by operating closer to resonance. Operation istypically within 10 Hz of resonance. As the frequency approaches theresonant condition, small changes produce large results.

The mixing vessel 60 is attached to payload mass 3. Vigorous mixing isachieved when the transmitted force is converted to acceleration anddisplacement amplitude thrusting the mix constituents up and downproducing a toroidal flow with sub-eddy currents.

In a further implementation, two more servo motors 38 are added to theresonant mixer 10 shown in FIGS. 1-4. The two additional servo motors 38are fitted with eccentric weights 56 having the same physicalcharacteristics as those above noted. The additional motors 38 maycontrol the impulse force. This may be accomplished by controlling therelative phase angle between the two sets of motors 38. In a similarmanner as described above, the two sets of servo motors 38 areelectrically controlled to accomplish total force cancellation throughall frequencies. After the desired frequency has been achieved, therelative phase angle between the two motor sets is changed until thedesired impulse force has been achieved. This arraignment has the addedadvantage of producing variable force and frequency.

In another implementation of the resonant mixer 10, the variableresilient members are substituted for the springs 24, 25, 26 and/or 27to provide for changes to the resonant frequency. This addition alsoallows for a larger variability in the payload without sacrificingperformance. The variable resilient members can be either mechanicallyor electronically controlled. Examples of such devices are air filledbellows, variable length leaf springs, coil spring wedges, piezoelectricbi-metal springs, or any other member which can be used as a resilientmember which also has the capability of having its spring rate changedor otherwise affected.

Rather than mix by inducing bulk fluid flow, as is the case for impelleragitation, the resonant mixer mixes by inducing micro-scale turbulencethrough the propagation of acoustic waves throughout the medium. It isdifferent from ultrasonic agitation because the frequency of acousticenergy is lower and the scale of mixing is larger. Another distinctdifference from ultrasonic technology is that the resonant mixerdevices, configured as show in FIGS. 1-4, are simple, mechanicallydriven agitators that can be made large enough to perform industrialscale tasks.

A difference between the acoustic agitation technology disclosed hereinand conventional impeller agitation is the scale at which completemixing occurs. In impeller agitation, the mixing occurs through thecreation of large scale eddies which are reduced to smaller scale eddieswhere the energy is dissipated through viscous forces. With acousticagitation, the mixing occurs through acoustic streaming, which is thetime-independent flow of fluid induced by a sound field. It is caused byconservation of momentum dissipated by the absorption and propagation ofsound in the fluid. The acoustic streaming transports “micro scale”eddies through the fluid, estimated to be on the order of 100-200 um.Although the eddies are of a microscale, the entire reactor is wellmixed in an extremely short time because the acoustic streaming causesthe microscale vortices to be transmitted uniformly throughout thefluid.

The resonant mixer 10 in FIGS. 1-4 may be operated at resonance toproduce intense displacement and acceleration so as to provide vigorousmixing potential. FIG. 5 shows an aspect of the response of resonantmixer 10 presented in FIGS. 1-4 to operation at various oscillatorfrequencies. The graph shows the force transmitted to the ground by theresonant mixer 10 when operated at each indicated frequency. Operationat the first harmonic frequency of the resonant mixer 10, illustrated aspoint A, and at the second harmonic frequency of resonant mixer 10,illustrated as point B, are indicated by the force peaks shown on thegraph. In operation, a user selects an operating frequency at or nearthe third mode (i.e., at or near the third harmonic frequency ofresonant mixer 10 or point C) as appropriate for the desired level ofmixing.

FIG. 6 shows another aspect of the response of the resonant mixer 10,illustrated in FIGS. 1-4, to operation at various oscillatorfrequencies. Specifically, FIG. 6 shows the phase of motion of thepayload mass 13 and the reaction mass (e.g., the intermediate mass 11).Above a frequency of about 40 Hz, the phase difference between thepayload mass 13 and the reaction mass is about 180 degrees, indicatingthat they are moving in opposite directions.

FIG. 7 shows another example of a three-mass system with a low-mountedvibration drive. In the low-mounted vibration drive system, theoscillator mass 12 and the payload mass 13 are situated at approximatelythe same elevation and both are above the intermediate mass 11. Thisillustrates that the relative locations of the masses can vary amongimplementations.

FIG. 8 shows another example of three-mass system with a middle-mountedvibration drive. In the middle-mounted vibration drive system, a singlelinear electromagnetic force transducer 38 is rigidly attached to themiddle of the oscillator mass 12. The oscillator mass 12 is movablyconnected to the intermediate mass 11 by the intermediate mass springs25. The payload mass 13 is movably connected to the intermediate mass 11by the springs 26. The intermediate mass 11 is movably connected to base37 by the ground springs 27.

Referring to FIG. 9A, a free body diagram of one implementation of theresonant mixer 10, illustrated in FIGS. 1-4, is presented. The followingare the equations of motion of resonant mixer 10m ₁ a ₁ =−k ₁ x ₁ −c ₁ v ₁ +k ₂(x ₂ −x ₁)+k ₃(x ₃ −x ₁)+c ₂(v ₂ −v ₁)+c₃(v ₃ −v ₁)m ₂ a ₂ =−k ₂(x ₂ −x ₁)−c ₂(v ₂ −v ₁)+Fm ₃ a ₃ =−k ₃(x ₃ −x ₁)−c ₃(v ₃ −v ₁)−k ₄ x ₃ −c ₄ v ₃

where:

-   -   m_(x)=mass x    -   m₁=payload mass    -   m₂=intermediate mass    -   m₃=oscillator mass    -   k_(x)=spring rate of spring x    -   c_(x)=damping coefficient of dash pot x    -   x_(x)=position of mass x    -   v_(x)=velocity of mass x    -   a_(x)=acceleration of mass x    -   F=applied force by solving these equations simultaneously,        appropriate weights for the masses and appropriate spring rates        and damping coefficients for the springs can be selected for        implementations of the invention. A person having ordinary skill        in the art would be capable of writing similar equations for        other embodiments of the invention.

There are an infinite number of solutions to the three equations ofmotion above which describe the motion of the three mass system ofresonant mixer 10. Optimization of the system is dependent upon thedesired operation of the system. In general, the selection of mass andspring sizes are subject to increasing payload amplitude, reducingforces transmitted to ground and decreasing driver amplitude. Oneimplementation uses spring ratios as follows; k1/k1=1, k2/k1=4.6,k3/k1=3.9, k4/k1=1.3, and mass ratios of; m1/m1=1, m2/m1=1.17,m3/m1=0.6. The dashpot constants are a result of natural damping in theimplementation and are not actual components. Therefore, the values ofdashpot constants may be determined by testing after an embodiment isfabricated.

Control of a three mass system includes two primary aspects. The firstaspect includes control of the phase angle or relative position of eachof the servo motors with respect to each other. The sensors for this arethe resolvers which are attached to the shaft of each motor. Thesedevices send an absolute position signal back to the motion controllerwhich tracks the position error from one motor to another. In turn, themotion controller then calculates and sends a correction signal back tothe motors. This keeps the motors phase angles within a tolerance whichis set in the control code.

The second aspect of the control system is the setting and maintenanceof a desired vibration amplitude. This is accomplished by monitoring theamplitude of the payload mass movements (m1) with an accelerometer. Thesignals from the accelerometer are sent to the motion controller and arecompared to a value set by the operator. An error correction signal isthen calculated and sent to the motors to increase or decrease theirfrequency and phase angle to achieve the desired amplitude.

Control of the phase angle of the motors also has two aspects. The firstaspect is to maintain motor-to-motor position and the second aspect isto control the magnitude of the force input to the system. Maintenanceof motor-to-motor position is necessary so that the resultant forceinput to the system is oriented in a single direction. This isaccomplished by controlling the position of motor pairs. The motors arepaired in twos or sets such that each set has identical phase angles.The motor pairs are then set in motion such that they have equal butopposite rotational frequencies. The phase position is then controlledin a manner that sums the resultant forces from the eccentric masses ina singular direction which is parallel to the orientation of the springaxes. Force magnitude is controlled by the controlling the phase anglebetween motor pairs. If the motor pairs are 180 degrees out of phasewith each other, the net resultant force is zero. When the phase anglebetween motor pairs is zero degrees, the net resultant force is 100percent of the summation of the four eccentric masses. Phase anglesbetween these extremes result in forces that are lower than the maximum.

FIG. 9B shows a free body diagram of another example implementation of aresonant acoustic mixer. The mixing system in FIG. 9B functions in asimilar fashion as the mixing system show in FIG. 9A, but theconfiguration is different. FIG. 9B shows a mixing system with a singlemass coupled to the ground through a single set of springs. Whereas FIG.9A includes two masses and two sets of springs coupled to ground.

The following are the equations of motion of the vibratory mixing systemshown in FIG. 9B:m ₁ a ₁ +k ₃(x ₁ −x ₂)+k ₁(x ₁ −x ₃)+c ₃(v ₁ −v ₂)+c ₁(v ₁ −v ₃)=0m ₂ a ₂ +k ₃(x ₂ −x ₁)+k ₂(x ₂ −x ₃)+c ₃(v ₂ −v ₁)+c ₂(v ₂ −v ₃)=Fm ₃ a ₃ +k ₁(x ₃ −x ₁)+k ₂(x ₃ −x ₂)+k ₄ x ₃ +c ₁(v ₃ −v ₁)+c ₂(v ₃ −v₂)+c ₄ v ₃=0

In addition to being used for mixing substances, the resonant acousticmixers described above can be configured for spray coating varioussubstances as described below. In some implementations, a resonantacoustic mixer can be a vibratory mixer. FIG. 10A-33 show schematicviews of various examples of vibratory mixer based spray coating systems100 a-100 w (generally coating systems 100). Each coating system 100includes a payload plate 102, a mixing vessel 104, and a sprayer 106.Such coating systems can mix, coat, dry, combine, and/or segregatematerials with low frequency, high intensity acoustic energy to fluidizethe materials being processed. The coating systems 100 can be equippedwith one or more optional components, such as temperature sensors,vacuum sources, pressure pumps, heating and cooling jackets, filters,temperature and mixedness sensors, and sieves to improve the mixers'ability to mix, coat, dry, combine, or segregate materials in variousapplications.

In general, the mixing systems 100 add small droplets (from nano to raindrop sized (˜6 mm)) of liquids or powders to a material that is beingagitated using an acoustic mixer similar to the mixers described above.Additional description of such mixers can be found in U.S. Pat. Nos.7,188,993 and 7,866,878, the entirety of which are incorporated hereinby reference.

FIG. 10A shows an example of coating system 100 a. The coating systems100 includes an acoustic mixer payload plate 102, a mixing vessel 104, asprayer 106, and a vacuum line 112. The coating systems 100 isconfigured to fluidize solid materials without the use of gaseous mediaby moving the mixing vessel 104 with displacement amplitudes between0.02 inch to about 0.5 inch. The mixing vessel 104 may be moved whilepositioned on top of the payload plate 102. The payload plate 102 iscapable of oscillating at operating frequencies between about 15 Hz toabout 1,000 Hz. For spray applications, the payload plate 102 isconfigured to frequencies of about 50 Hz to about 70 Hz. For some sprayapplications, in some implementations, the payload plate 102 mayoscillate up to an operating frequency of about 180 Hz. In oneimplementation, the payload plate 102 may oscillate at an operatingfrequency of about 60 Hz.

During operation, the coating systems 100 may cause a material to becoated to become a fluidized bed due to the high acoustic energyproduced from the payload plate 102 oscillating under the mixing vessel104. In one implementation, the coating systems 100 forms a fluidizedbed of solid materials when the mixing vessel 104 is under pressure,atmospheric pressure, or under partial or full vacuum. When a fullvacuum is applied, the fluidized bed may be formed byparticle-to-particle interaction. In some implementations, the primarymixing mechanism may be from collisions that are driven byinter-particle redistribution. Collision-related mixing processes mayincrease with higher accelerations. In some implementations, the mixingis done without acoustic interaction because there is no media gasses tocarry an acoustic wave. As discussed further below, the coating systems100 has been demonstrated to form a fluidized bed on hard to fluidizematerials, where typical gaseous fluidizers rat hole or create plugflow.

The mixing vessel 104 may contain the material to be coated. The mixingvessel 104 may be any type of container used for mixing, combining,segregating, coating or drying materials. Additionally, the mixingvessel 104 may be of any size that can fit within the acoustic mixer. Inone implementation, the mixing vessel 104 may be a small micro wellplate. In another implementation, the mixing vessel 104 may beconfigured to hold up to 500 gallons of materials. In otherimplementations, the mixing vessel 104 has an intermediate size. In oneimplementation, the mixing vessel 104 may be filled no more than 90% ofthe maximum volume during operation. The material may be a powder, aliquid or combination of a powder and a liquid material.

The sprayer 106 is configured to direct a coating material 110 onto auniformly fluidized bed, as illustrated in FIG. 10A. The sprayer 106 mayintroduce the coating material 110 into the mixing vessel 104. Thesprayer 1006 may be any device for emitting materials in liquid or solidform. In one implementation, the sprayer 106 may be an atomizer. Thesprayer 106 may be positioned along a top portion of the mixing vessel104. In some implementations, the sprayer 106 may be positioned adjacentto a side of the mixing vessel 104 (see FIG. 27). In still anotherimplementation, the sprayer 106 may be coupled to the bottom of themixing vessel 104 (see FIG. 19). FIG. 10B shows another example coatingssystems 100 a, wherein the sprayer 106 is not directly coupled to themixing vessel 104 and still introduces the coating material 110 into themixing vessel 104.

Many different types of sprayers 106 may be used in conjunction with thecoating systems 100. The particle sizes of the coating material 110released from the sprayer 106 can be from nano-sized to rain drop sized.Industry standard atomizers or sprayers, including pressure atomizers(e.g., plain orifice, pressure-swirl, square spray, duplex, spillreturn, and fan spray), rotary, air-assist, airblast, electrostatic,ultrasonic, sonic, windmill, vibrating capillary, flashing liquid jet,effervescent, and/or piezoelectric atomizers may be coupled with thecoating systems 100. The type of nozzle as well as the fluid parametersof density, viscosity, and surface tension play a large role in the sizeof fluid particles being sprayed from the nozzles and can be varieddepending on the particular coating application undertaken.

As shown in FIG. 10A, in some implementations, the vacuum line 112 maybe coupled to the mixing vessel 104 and introduce a vacuum source to themixing vessel 104. The vacuum source may effect the pressure in themixing vessel 104. The vacuum source can create partial or full vacuumin the mixing vessel 104 dependent upon the type of materials involvedand the desired application.

The fluidized bed created by the coating systems 100 may have moreconsistent material turnover as compared to gas driven fluidized bedsbecause of uniform bulk mixing. The bulk mixing provides top to bottomcirculation of the materials in the mixing vessel or reactor. FIGS. 11and 12 display illustrative examples of two traditional bulk mixing flowpatterns. In FIG. 11, the bulk flow pattern travels up the center of themixing vessel 104 and down the sides. In FIG. 12, the bulk flow patterntravels up the sides of the mixing vessel 104 and down the center.Different flow patters' may be caused by material interactions withinthe mixing vessel 104. The material interactions may be caused by theshape of the mixing vessel 104, including the shape of the walls, topand bottom of the mixing vessel 104. In some implementations, a thirdmaterial may be introduced inside the mixing vessel 104 to create adifferent bulk flow pattern. The third material may be a baffle or anytype of material to change, direct or affect the flow of the materialmixing inside the mixing vessel 104.

The acoustic mixer can cause both micro-mixing of the particles as wellas bulk mixing of the particles within the mixing vessel 104. Micromixing of the particles results from particle-to-particle andparticle-to-vessel interactions. The partial-to-particle interactioncauses micro-mixing that induces diffusion like phenomena andsegregation of the particles. The diffusion-like phenomena correspondsto side-to-side exchange of particles, where the segregation correspondsto an up-and-down exchange of particles. Micro-mixing, as well as thebulk mixing, allows for new materials to come into exposure with a finespray mist output by the sprayer 106. In some implementations,micro-mixing alone will lead to segregated materials within the vessel.The micro-mixing of the particles can contribute to and drive the bulkmixing of the materials. The combination of the micro and bulk mixing ofthe materials may very rapidly mix the materials and move the entirecontents of the mixing vessel through a single or multiple fine spraymists rapidly.

Referring back to FIG. 10A, when spraying into a fluidized bed createdunder vacuum conditions using the coating systems 100, the coatingmaterial 110 introduced by the sprayer 106 can be can be sprayed withoutexhibiting drag onto the particles.

FIG. 13 shows a second example coating system 100 b, operated underatmospheric conditions. Instead of a vacuum line 112, the coating system100 b includes a vent 118 coupled to the mixing vessel 104 to maintainthe atmospheric conditions inside the mixing vessel 104. The vent 118may be any device or outlet for allowing air into and out of the mixingvessel 104. In another example coating system 100 c, shown in FIG. 14,the mixing vessel 104 is sealed maintaining an increased pressure withinthe mixing vessel 104.

FIG. 15 shows a fourth example coating system 100 d. The coating system100 d includes a pressure relief valve 120. The pressure relief valve120 may be coupled to the mixing vessel 104 and may be used to controlthe pressure levels in the mixing vessel 104. In some implementations,the pressure relief valve may keep the pressure substantially constantduring the spray process. In one implementation, the pressure reliefvalve 120 is coupled to the top of the mixing vessel 104. In otherimplementations, the pressure relief valve may be coupled to any side ofthe mixing vessel 104. The pressure relief valve 120 can be configuredto maintain pressures at or above atmospheric pressure.

FIG. 16 shows another example coating systems 100 e. The coating system100 e is similar to the coating system 100 a. However, the coatingsystem 100 e also includes a cooling jacket 122 coupled to the mixingvessel 104. The cooling jacket 122 includes a cooling inlet 123 a and acooling outlet 123 b. During operation of the coating system 100 e, workis being performed on the fluidized materials from mechanical motioncaused by particle-to-particle collisions as well as particleinteraction with the walls. In some implementations, this work on thefluidized materials may be dissipated as heat. The heat may be unwantedand a cooling mechanism, such as the cooling jacket 122, can be appliedaround the mixing vessel 104 to keep the material contents at a desiredtemperature during the process. In some implementations, it may bedesirable to carry out the processes at temperatures below roomtemperatures. The cooling jacket can help achieve this operatingcondition, too.

In another example coating system 100 f, shown in FIG. 17, the coatingsystem 100 f includes a heating jacket 124 coupled to the mixing vessel104. In some implementations, it may be desirable to maintain anincreased temperature in the mixing vessel 104, e.g., to maintain adecreased viscosity of a sprayed-in material, or to facilitate drying ofthe material. As such, a heating mechanism, such as the heating jacket124 or band heaters, can be applied around the mixing vessel 104 to keepthe material contents at a desired temperature during any process. Aswith the cooling jacket shown in FIG. 16, the heating jacket 124 caninclude an inlet 125 a and an outlet 125 b for receiving and releasing aheating fluid such as a hot gas or liquid.

FIG. 18 shows a seventh example coating system 100 g. The coating system100 g is similar to coating system 100 a, but is used for dryingapplications and includes a gas sweep 126 coupled to the mixing vessel104. To dry the materials in the mixing vessel 104, a gas, in lowvolume, may be used for reaction with the solid materials inside themixing vessel 104. In some implementations, the sweep gas feed 126 maybe coupled to top of the mixing vessel 104. In other implementations,the sweep gas feed may be coupled to the any side of the mixing vessel104. In still another implementation, the sweep gas feed 126 may becoupled to the bottom of the mixing vessel 104. The configuration ofcoating system 100 g allows for little to no excess reaction gas to beneeded for the fluidization of the particles, because the fluidizationis mechanical and does not require a gas, which would be wasted using atraditional gas fluidizer.

FIG. 19 shows another example coating system 100 h used in dryingapplications. The coating system 100 h is similar to coating systems 100g, described above, but the sprayer 106 is coupled to the bottom of themixing vessel 104 instead of the top. The sweep gas feed 126 is coupledto the top of the mixing vessel 104. The sprayer 106 coupled to thebottom of the mixing vessel 104 can introduce the coating material 110through the bottom of the mixing vessel 104.

FIG. 20 also shows another example coating system 100 i that can be usedin drying applications. The coating system 100 i includes the sweep gasfeed 126 coupled to the bottom of the mixing vessel 104 and the sprayer106 may be coupled to the top of the mixing vessel 104. In thisimplementation, the sweep gas may be introduce gas through the bottom ofthe mixing vessel 104 and under the contents. In other implementationsthe sweep gas feed 126 may be coupled to any location on the mixingvessel 104. The various placements of the sweep gas feed 126 and thesprayer 106 on the mixing vessel 104 can depend on the type of materialsbeing mixed and the type of coating materials being used. Some materialstend to float to the top of the mixing vessel during mixing and sprayingapplications, while others tend to sink to the bottom of the mixingvessel 104. To uniformly and evenly mix and coat certain materials itmay be desirable to introduce the coating materials and drying gas atdifferent locations and angles.

In some implementations, to accommodate the various sprayer 106 andsweep gas feed 126 configurations, the mixing vessel 104 may include anumber of ports at various locations around its exterior. Each portallows for the coupling of a sweep gas line 126 or a sprayer 106. Theports can also be sealed if not in use for a particular application.

FIG. 21 shows another example coating system 100 j. The coating system100 j is similar to coating system 100 a, but the coating system 100 jincludes a filter 128. The filter 128 may be coupled to the vent 118shown in FIG. 13, the pressure relief valve 120 shown in FIG. 15 or thevacuum line 112 shown in FIGS. 10-12. The filter may block or inhibitunwanted materials from passing through the vent 118, the pressurerelief valve 120 or the vacuum line 112 during coating applications.

FIG. 22 shows an eleventh example coating system 100 k. The coatingsystem 100 k can also be used for spraying and drying applications andis configured to introduce coating materials according to the WursterMethod. The coating system 100 k includes a sprayer 106 coupled to thebottom of the mixing vessel 104, a sweep gas feed 126 coupled to the topof the mixing vessel 104 and a vent 118 coupled to the top of the mixingvessel 104. In the Wurster method the sprayer 106 is located at thebottom of the mixing vessel and introduces the coating material 110through a nozzle that sprays the coating material 110 above thematerials to be coated and allows the sprayed material to fall onto thefluidized bed. The process uses a partition to separate the separatedparticles that have just been sprayed and those that have been sprayed.The particles dry when they are falling back to the fluidized bed toprevent agglomeration.

FIG. 23 shows another example coating system 1001. The coating system1001 is similar to the coating system 100 a, but includes a temperaturemeasuring device 130. The temperature measuring device 130 may be addedto the mixing vessel 104 to monitor the temperature of the materials inthe mixing vessel 104. In some implementations, as show in FIG. 24Adepicting a coating system 100 m, a plurality of temperature measuringdevices 130 may be applied to the mixing vessel 104. The temperaturemeasuring devices 130 may be applied at different depths and locationsto determine if the materials are being uniformly fluidized, mixed orcoated. The temperature measuring devices 130 used in the coatingsystems 1001 and 100 m may be any device that measures temperatureincluding temperature sensors, thermocouples, resistance temperaturedetectors (RTD), thermistor, or infrared detectors.

FIG. 24B shows a graph of temperature readings received from thetemperature measuring device 130. The readings can be from the coatingsystem 100 or the continuous flow reactor system 200. When the materialsare uniformly fluidized or mixed the multiple temperature readings willtend toward each other and be closer in value. When the mixing orfluidizing stops, then the temperatures of the various temperaturereaders will diverge.

FIG. 25 shows a fourteenth example coating system 100 n. Instead ofincluding a temperature measuring device 130 to monitor the process, asshow in FIGS. 23 and 24, the coating system 100 n includes anear-infrared (NIR) mixedness sensor 132. The mixing stages and coatingprocess can be monitored in real-time by the use of detectors such asthe NIR sensors 132, such as those available from Goodrich ISR Systems(Princeton, N.J.) that are used to perform a NIR spectroscopy. The NIRsensors 132 can view the materials mixing in the mixing vessel 104though a NIR transparent material. The NIR spectroscopy can be used todetermine mixedness and the current mixing stage of the materials in themixing vessel 104. The NIR spectroscopy may also determine when thematerials are sufficiently coated, wet, dry, or reacted.

In the many examples of the coating systems 100 described herein, theshape of the nozzle of the sprayer 106 may be of various shapes, forexample and without limitation, a cone, ring, and a straight jet. FIG.26 shows an example coating system 100 o. The coating system 100 o issimilar to the coating system 100 a, but includes a sprayer 106 with astraight jet nozzle to introduce coating material 110 onto the fluidizedbed in the mixing vessel 104. The type of nozzle chosen for eachapplication can depend on the type of material to be coated and the typeof coating material 110 to be used.

Additionally, the coating systems 100 can have a single sprayer 106coupled to the mixing vessel 104 or a plurality of sprayers 106 coupledto the mixing vessel 104. The sprayer(s) 106 can also be coupled to theat various angles. FIG. 27 shows an example coating system 100 p. Thecoating system 100 p includes a plurality of sprayers 106 coupled todifferent locations on the mixing vessel 104, instead of only onesprayer 106 coupled to the top of the mixing vessel 104, as shown incoating system 100 a. The plurality of sprayers 106 may introduce thecoating material 110 into mixing vessel 104 at various locations andangles dependent upon the desired application and materials used. InFIG. 27, a first sprayer 106 is coupled to the side of the mixing vessel104 to introduce the coating material 110 onto the top of the fluidizedbed 108 inside the mixing vessel 104 and a second sprayer 106 is coupledto the bottom of the mixing vessel 104 to introduce a material under thefluidized bed 108. FIG. 28 shows another example coating system 100 qthat includes a plurality of sprayers 106. The coating system 100 qincludes the plurality of sprayers 160 all coupled to the top of themixing vessel 104.

FIG. 29 shows another example coating system 100 r. The coating system100 r is similar to coating system 100 a, but includes a third material136 inside the mixing vessel 104 to affect the bulk flow pattern of thefluidized materials. The third material 136 can be any structure toaffect, change or direct the bulk flow pattern inside the mixing vessel104, including a baffle. The third material 136 can also be used toshield mixing vessel 104 ports from coming into contact with materialthat may splash up during mixing or coating applications. FIG. 30 showsan example coating system 100 s, which includes a vacuum line 112 withthe third material 136 (i.e., port baffles) shielding it. The coatingsystem 100 s is similar to the coating system 100 r, but the thirdmaterial is used to shield the ports on the mixing vessel 104 instead offor altering the mixing patterns within the mixing vessel 104. Similarbaffles can also shield ports of the vent 118 and the pressure reliefvalve 120. In some other implementations, the third material 136 cancreate a path for materials to flow out of the mixing vessel 104 and outof any of the ports.

In the many example coating systems 100 described herein, the mixingvessel 104 can be configured in various shapes and forms according tothe desired application. FIG. 31 shows another example coating system100 t. The coating system 100 t includes a mixing vessel 104 with aspherical bottom 140. Different shapes of the mixing vessel 104 can beused to mitigate dead zones or caking of materials in the mixing vessel104. In another example coating system 100 u, shown in FIG. 32, themixing vessel 104 can have a generally conical shape 142. The variousshapes of the top, walls and bottom of the mixing vessel 104 can alsoaffect the bulk flow patterns and be selected based on a desired bulkflow pattern.

FIG. 33 shows an example continuous flow reactor system 200. Thecontinuous flow reactor system 200 can fluidize powders or materials ina continuous flow reactor 202, while one or more coating materials 110are applied at various stages. By adding the coating material in acontinuous or pulsed fashion while mixing the combined materials, clumpsand highly viscous regions can be mitigated. The continuous flow reactorsystem 200 includes a plurality of sprayers 206 coupled to the sides ofthe continuous flow reactor 202 and a plurality of material inlets 210to introduce coating materials 110 at various stages. In someimplementations, only one sprayer 206 is coupled to the continuous flowreactor 202. In some implementations, only one material inlet 210 iscoupled to the continuous flow reactor 202. The material to be coatedcan flow through the continuous flow reactor 202 and can be sprayed atvarious stages by the plurality of spray nozzles 206. Additional coatingmaterials 110 may be added at various stages and after the previousspray process through the material inlets 210. This may be advantageousbecause some materials may not need all the coatings and may allow forvarious materials to be added without coatings. The continuous flowreactor system 200 can be applied to many applications, for example andwithout limitation, mixing, coating, chemical reactions, combining, orsegregating materials. Some of the aforementioned applications aredescribed in more detail below.

The coating systems 100 and continuous flow reactor system 200 may beutilized in spray coating operations because they have excellentfluidization characteristics. Coatings are traditionally applied byadding sprayers or nozzles to fluidizers and tumblers. These methodswork well for large particles such as tablets. However, when trying tocoat smaller particles uniformly, pneumatic fluidizers and tumblers donot adequately create a uniform motion to coat the materials evenly. Thecoating systems 100 and continuous flow reactor system 200 haveexcellent fluidization characteristics for use with hard to fluidizematerials that include cohesive powders which tend to rat hole andexhibit plug flow if fluidized with standard fluidizers.

As materials become smaller and smaller they tend to become morecohesive. One example category of materials that exhibit this phenomenonincludes Pharmaceutical materials which are typically very cohesive.Typical active pharmaceutical ingredients (API) fall within particlesize and Geldart groups of powders. The Geldart Groupings of powders wasfirst used by Professor Geldart to describe and characterize differentpowders on how they fluidize in pneumatic driven fluidizers. Group Cpowders are powders that are in any way cohesive. It is extremelydifficult to fluidize Group C powders using conventional fluidizers suchas a pneumatic bed, and a vibratory pneumatic bed because the powderseither lift as a plug in small diameter tubes, or channels (rat-holes).Mechanical agitation can be applied to help avoid the aforementionedphenomena, but is not guaranteed to work. Plug flow causes nofluidization and channels only cause local fluidization which are bothunwanted for spray coating applications, because without constantuniform turnover of the material, the spray will cause liquid richzones, that form clumps.

By using a coating system, such as any of the coating systems 100described above, to uniformly fluidize the material, a sprayer will beable to be used to continuously spray on coating material and avoid theformation of clumps. Because the coating systems 100 does not usepneumatics to form the fluidized bed 108, the spray can be applied undernear vacuum conditions.

The coating systems 100 is well suited to create fluidized beds fromnano-sized particles to particles the size of tablets. Because thefluidization is formed from only vibration, the coating system 100 canfluidize nano-particles and all sizes of particles up to tablets withinits 0 g-200 g acceleration range and operating frequencies from about 50Hz to about 70 Hz. In one implementation, the payload plate 102 mayoscillate at an operating frequency of about 60 Hz. In some otherimplementations, the payload plate 102 may oscillate up to an operatingfrequency of 180 Hz. In some implementations, the coating system 100operates with an acceleration range of up to 100 g.

The sprayer 106 may spray a fluid, powder, or any combination. Becausethe coating systems 100 doesn't use pneumatics to create the fluidizedbed 108, the mixing vessel 104 holding the fluidized bed 108 may beclosed or sealed, which allows for small powders, such as nano-materials110 to be sprayed into the fluidized bed 108 without having thefluidization gasses trying to pull them out of the fluidized bed 108.

In performing chemical reactions the time required and the efficiencyare very critical as both cost money. The present disclosure includes amethod to mechanically fluidize particles by using the coating systems100 and coupling a sprayer 106. The sprayer 106 may be used to input agas or a liquid that will react with the fluidized materials 108. Thistechnology can be used with materials that need to react with aparticular gas or liquid material, but will react to air if used as thefluidizing media with conventional fluidizers. With normal gasfluidizers, the reaction gas is used for the reaction as well as for thefluidization, wasting the reaction material. By using a mechanicallyfluidized medium, such as is produced using the spray coating systems100 described above, the exact amount of reaction material can be addedto the mixing vessel 104. The reactants can then be allowed to reactduring fluidization without the addition of other materials to createthe fluidization, as would be needed using conventional fluidizers. Suchother added materials can potentially add contaminants, as well as wastematerials that would have normally been reacted, if a sealed vessel wasused.

The coating systems 100 a can be applied in many applications. Someexamples of different industries and application that can benefit fromthe technology are described in below.

Spray Coating and Drying

In a first example, the coating systems 100 a can be used in spraycoating and drying applications, including the food, pharmaceutical, andindustrial industry. Traditional spray dryers are used in manyindustries, but the main industries are food, pharmaceutical, andindustrial. Some examples use cases in each industry include theproduction of milk powder, coffee, tea, cereal, and spices for the foodindustry; antibiotics, medical ingredients, and additives for thepharmaceutical industry; and paint pigments and ceramic materials forthe industrial industry. Spray drying applications may use similar ifnot the same equipment as specified previously for coating applications.

Another well-known coating method in Pharmaceuticals is the Wurstermethod. The method uses a nozzle to spray a material onto particles thathave been separated from each other with a higher velocity gas streamthan is used to fluidize the particles. The process uses a partition toseparate the separated particles that have just been sprayed and thosethat have been sprayed. The particles dry when they are falling back tothe fluidized bed to prevent agglomeration.

Typical problems with the above systems is that they do not produceuniform fluidization and flow of the materials being coated and dried.This causes non-uniform coating and clumps of liquid rich materials,both of which are unwanted. The fluidization process employed by coatingsystems 100 described above can mitigate this process. The coatingsystems 100 fluidize materials ranging from nano-sized powder particlesup to tablet-sized particles.

FIG. 34 shows an example application of the coating system 100 a. Moreparticularly, FIG. 34 shows an expanded view of the coating system 100 aused for the coating of a sample API, in this case ibuprofen. Inaddition to the components of the coating system 100 a shown in FIG.10A, FIG. 34 also shows a feed line 146 from a tank 144 holding thecoating material 110. The tank 144 is coupled to a cabinet 148 toprovide controls for the tank 144. A hood 150 is shown in FIG. 34 toprotect the sprayer 106 introducing the coating material 110 and providea shield over the coating system 100 a. Additionally, FIG. 34 shows thevacuum feed 112 coupled to the mixing vessel 104.

In one experiment, a sample API material (ibuprofen) was coated with apolymer (Ibuprofen 70, BASF Corporation, Bishop Tex.). A picture of APImaterial coated by a traditional spray drying system is displayed inFIG. 35, with an optical microscope picture and a SEM image in the lowerright. The traditional spray drying system coated the API materialaround the diameter, but the ends were left uncoated and agglomerationsof many particles were formed. By using the coating system shown in FIG.34, the ibuprofen crystals were coated with the polymer and the endswere also coated. The coated particles also did not agglomerate. Apicture of the coated ibuprofen using an optical microscope is displayedin FIG. 36 and an SEM image is displayed in the lower right.

Spray Misting Applications

In a second first example, the coating systems 100 can be used in aspray misting application to combine finely dispersed liquids intosolids (powders) to make a paste. It is well known in baking that if allliquids are added to solids (powders) and then mixed, the end resultwill likely have clumps of dry powder or highly viscous regions. Byadding the liquid in a continuous additions or pulsed additions whilemixing the clumps and highly viscous regions can be mitigated.

The coating systems 100 are designed for batch mixing. All of the drymaterials can be added into the mixing vessel 104 prior to being mixed.In some implementations, by adding a nozzle to the mixing vessel 104,liquids may then be added by pulses or through a continuous flow intothe mixing vessel 104 while the mixing is being performed and mitigatethe clumps or highly viscous regions. The flow rate, nozzle type, numberof nozzles, location of nozzle(s), intensity of mixing, as well as manyother system and material properties may affect the mixture and themixing outcome.

In mixing high viscous liquids with powders, the high viscous materialmay not flow or mix appropriately. In the present disclosure utilizingthe coating systems 100, powder may be mixed in a mixing vessel 104vessel and the high viscous material may be added through a sprayer 106.The powder is then mixed with the high viscous material.

In a third example, the coating system 100 a can be used to combinefinely dispersed solids (powders) into liquids to make a paste. Whentrying to mix liquids and solids together, if all the ingredients areadded into the mixer all at one time the solids may become coated by theliquid and stay in unmixed dry clumps. The dry clumps can be broken upwith enough shear, but some powders are very shear sensitive and ifthese clumps form, then the particles will break during the breakage ofthe clumps. Through diffusion, liquid can permeate into the dry clumpsover time, which typically makes the clumps much harder and moredifficult to break up. When wetted, hard clumps are formed using shearsensitive powders, damage will occur if these clumps are broken up afterthey are formed. Therefore, when using shear sensitive materials it isimportant to avoid forming clumps when mixing. In one implementation ofthe present system, by adding the powders slowly while the liquid ismixing, the coating systems 100 may mix the powder into the liquidwithout forming clumps.

Spray Coating of Liquids with Powder Applications

In a fourth example, the coating systems 100 a can be used for spraycoating of liquids with powders, such as in the cosmetics industry. Inthe cosmetics industry, fine droplets of liquids covered with powder areused to put on foundation. The droplets are shear sensitive in that thedroplets act like a powder because they are coated with powder untilthere is enough shear to free the liquid from its powder coating. Thus,when the powder coated liquid is applied as a powder, it smears onto theskin like a cream. In another implementation of the present disclosure,a method to make the material includes spray coating a liquid with apowder, by spraying a fine mist of droplets into a fluidized bed ofpowder created by the coating systems 100. The vessel can have a full orpartial vacuum, which will make the droplets tend to stay apart and notjoin into larger particles during the spraying process. Each dropletwill permeate the powder-fluidized bed and become coated before thelater introduced liquid droplets have a chance to catch up and join withthe droplets.

Spray Coating of Powders onto Powder

In a fifth example, the coating systems 100 a can be used for spraycoating of powders onto powders. This technology may be applied in thepolymer industry where materials are alloyed. The materials that arealloyed need to all be fed into a polymer extruder at a constantmaterial constituent rate or else the polymer material will vary inmaterial and mechanical properties. Many of the alloying materials areof small amounts and can be of small particle size. The coating systems100 can be used to coat the smaller amounts of alloying materials ontothe parent material with the use of sprayers 106, spraying the alloyingmaterial onto a fluidized bed 108 of parent material. This allows thecorrect amount of material to be fed into the extruder to compound thealloying material.

Additionally, this technology can also be applied to the pharmaceuticalindustry in adding small amounts of API to a parent material. Thetechnology can also be extended to use in the coloring industry as wellas the food and spice industries.

While the disclosure has been disclosed in connection with theembodiments shown and described in detail, various modifications andimprovements thereon will become readily apparent to those skilled inthe art. Accordingly, the spirit and scope of the present disclosure isto be limited only by the following claims.

What is claimed is:
 1. A system for mixing a plurality of materials,comprising: a mixing vessel configured for holding a first materialtherein; a vibratory mixer configured to oscillate at a range of about50 Hz to about 70 Hz with a displacement amplitude of about 0.02 inchesto about 0.5 inches, thereby generating a fluidized bed of the firstmaterial in the mixing vessel at a location, the vibratory mixerincluding a payload plate having a plane and configured to oscillate anentirety of the mixing vessel in a substantially linear directionperpendicular to the plane of the payload plate; and at least one spraynozzle configured for introducing a second material into the mixingvessel at the location.
 2. The system of claim 1, wherein the mixingvessel is sealed to maintain the pressure therein.
 3. The system ofclaim 1, wherein the at least one spray nozzle is coupled directly to atleast one of a top portion, a side portion, or a bottom portion of themixing vessel.
 4. The system of claim 1, wherein the mixing vessel isfurther configured to mix the first and second material in a bulk flowpattern.
 5. The system of claim 4, wherein the bulk flow patterncomprises micro mixing of the first material and the second material. 6.The system of claim 1, further comprising a sweep gas feed lineconfigured to introduce a drying gas into the mixing vessel.
 7. Thesystem of claim 1, further comprising a mixedness sensor configured todetect mixedness of the first material and the second material in themixing vessel.
 8. The system of claim 1, further comprising a filtercoupled to at least one of a vent, a pressure relief valve, or a vacuumline, and configured to block an unwanted material from passingtherethrough.
 9. The system of claim 1, further comprising a coolingjacket coupled to the mixing vessel and configured to cool the mixingvessel.
 10. The system of claim 1, further comprising a heatingmechanism coupled to the mixing vessel and configured to heat the mixingvessel.
 11. The system of claim 1, further comprising a temperaturesensor coupled to the mixing vessel and configured to detect atemperature of at least one of the first or the second material in themixing vessel.